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Manual Transaxle ASSY (C60): Overhaul

WARNING: This page is about a different variant/trim than selected.
  1. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY 
    1. Remove the bolt and speedometer driven hole cover sub-assy.
    2. Remove the O-ring from the speedometer driven hole cover sub-assy.
  2. REMOVE CLUTCH RELEASE FORK SUB-ASSY 
    1. Remove the clutch release fork sub-assy with the clutch release bearing assy from the transaxle case.
    Fig 1: Removing Clutch Release Fork Sub-Assy
    G02614706Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. REMOVE CLUTCH RELEASE BEARING ASSY 
    1. Remove the clutch release bearing hub clip and clutch release bearing assy from the clutch release fork sub-assy.
    Fig 2: Removing Clutch Release Bearing Assy
    G02614707Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. REMOVE RELEASE FORK SUPPORT 
    1. Remove the release fork support from the transaxle case.
    Fig 3: Removing Release Fork Support
    G02614708Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE CLUTCH RELEASE FORK BOOT 
    1. Remove the clutch release fork boot from the transaxle case.
    Fig 4: Removing Clutch Release Fork Boot
    G02614709Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET 
    1. Remove the 3 bolts and floor shift control lever housing support bracket from the transaxle case.
    Fig 5: Removing Bolts Floor Shift Control Lever Housing Support Bracket
    G02614710Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE SELECTING BELL CRANK ASSY 
    1. Remove the 2 bolts and selecting bell crank assy from the manual transmission case.
    2. Remove the control shift lever bush.
    Fig 6: Removing Control Shift Lever Bush
    G02614711Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. FIX MANUAL TRANSAXLE ASSY 
    1. Place the manual transaxle assy on wooden blocks.
    Fig 7: Placing Manual Transaxle Assy On Wooden Blocks
    G02614712Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE MANUAL TRANSMISSION FILLER PLUG 
    1. Remove the manual transmission filler plug and gasket from the manual transmission case cover.
    Fig 8: Removing Manual Transmission Filler Plug
    G02614713Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE DRAIN (MTM) PLUG SUB-ASSY 
    1. Remove the drain (MTM) plug sub-assy and gasket from the manual transmission case.
    Fig 9: Removing Drain Plug
    G02614714Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE MANUAL TRANSMISSION CASE COVER SUB-ASSY 
    1. Remove the 9 bolts.
      Fig 10: Removing Bolts
      G02614715Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, remove the manual transmission case cover sub-assy.
    NOTE: Do not damage the manual transmission case cover sub-assy.
    Fig 11: Removing Manual Transmission Case Cover Sub-Assy
    G02614716Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSPECT 6th GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 6th gear thrust clearance.

      Standard clearance: 

      0.10 to 0.60 mm (0.0039 to 0.0236 in.) 

    Fig 12: Measuring 6th Gear Thrust Clearance
    G02614717Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSPECT 5th GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 5th gear thrust clearance.

      Standard clearance: 

      0.10 to 0.62 mm (0.0039 to 0.0244 in.) 

    Fig 13: Measuring 5th Gear Thrust Clearance
    G02614718Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSPECT 6th GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 6th gear radial clearance.

      Standard clearance: 

      0.009 to 0.050 mm (0.0004 to 0.0020 in.) 

    If the clearance is out of specification, replace the 6th gear needle roller bearing.

    Fig 14: Measuring 6th Gear Radial Clearance
    G02614719Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSPECT 5th GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 5th gear radial clearance.

      Standard clearance: 

      0.015 to 0.056 mm (0.0006 to 0.0022 in.) 

    If the clearance is out of specification, replace the 5th gear needle roller bearing.

    Fig 15: Measuring 5th Gear Radial Clearance
    G02614720Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  16. REMOVE COUNTER GEAR 6th 
    1. Using 2 screwdrivers and a hammer, remove the output shaft RR snap ring from the output shaft.

      HINT:

      Use a shop rag to keep the snap ring from flying.

      Fig 16: Removing Output Shaft RR Snap Ring
      G02614721Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the output shaft RR bearing with the counter gear 6th from the output shaft.

      SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011), 09950-60010 (09951-00190)

    Fig 17: Removing Output Shaft RR Bearing
    G02614722Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. REMOVE OUTPUT GEAR SPACER 
    1. Remove the output gear spacer from the output shaft.
    Fig 18: Removing Output Gear Spacer
    G02614723Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. REMOVE 6th GEAR SUB-ASSY 
    1. Using 2 screwdrivers and a hammer, remove the input shaft snap ring from the input shaft.
      NOTE: Use a shop rag to keep the snap ring from flying.
      Fig 19: Removing Input Shaft Snap Ring
      G02614724Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the input shaft radial ball bearing RR with the 6th gear sub-assy from the input shaft.

      SST 09950-40011 (09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011)

    Fig 20: Removing Input Shaft Radial Ball Bearing
    G02614725Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  19. REMOVE 6th GEAR NEEDLE ROLLER BEARING 
    1. Remove the 6th gear needle roller bearing from the input shaft.
    Fig 21: Removing 6th Gear Needle Roller Bearing
    G02614726Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  20. REMOVE SYNCHRONIZER RING NO.3 (FOR 6th GEAR MT) 
    1. Remove the synchronizer ring No.3 from the input shaft.
    Fig 22: Removing Synchronizer Ring
    G02614727Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  21. REMOVE TRANSMISSION CLUTCH HUB NO.3 
    1. Remove the 6th gear spacer.
    2. Using 2 screwdrivers and a hammer, remove the transmission clutch hub No.3 shaft snap ring from the input shaft.
      NOTE: Use a shop rag to keep the snap ring from flying.
      Fig 23: Removing Transmission Clutch Hub
      G02614728Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the shift fork lock bolt from the shift fork No.3.
      Fig 24: Removing Shift Fork Lock Bolt
      G02614729Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST, remove the transmission clutch hub No.3 with the gear shift fork No.3 from the input shaft.

      SST 09950-30012 (09951-03010, 09953-03010, 09957-04010), 09950-50013 (09954-05040)

    Fig 25: Removing Transmission Clutch Hub
    G02614730Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. REMOVE SYNCHRONIZER RING NO.3 (FOR 5th GEAR MT) 
    1. Remove the synchronizer ring No.3 from the 5th gear.
    Fig 26: Removing Synchronizer Ring
    G02614731Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. REMOVE 5th GEAR 
    1. Remove the 5th gear from the input shaft.
    Fig 27: Removing 5th Gear From Input Shaft
    G02614732Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  24. REMOVE 5th GEAR NEEDLE ROLLER BEARING 
    1. Using 2 screwdrivers and a hammer, remove the transmission clutch hub No.3 shaft snap ring from the input shaft.
      NOTE: Use a shop rag to keep the snap ring from flying.
      Fig 28: Removing Transmission Clutch Hub
      G02614733Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 5th gear needle roller bearing and two 5th gear bearing spacers from the input shaft.
    Fig 29: Removing 5th Gear Needle Roller Bearing
    G02614734Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  25. REMOVE 5th DRIVEN GEAR 
    1. Using SST, remove the 5th driven gear from the output shaft.

      SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09957-04010), 09950-60010 (09951-00190)

    Fig 30: Removing 5th Driven Gear
    G02614735Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  26. REMOVE SHIFT FORK SHAFT SNAP RING 
    1. Using 2 screwdrivers and a hammer, remove the shift fork shaft snap ring from the shift fork shaft No.2.
    NOTE: Use a shop rag to keep the snap ring from flying.
    Fig 31: Removing Shift Fork Shaft Snap Ring
    G02614736Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  27. REMOVE BEARING RETAINER REAR (MTM) 
    1. Remove the 5 bolts and bearing retainer rear (MTM) from the manual transmission case.
    Fig 32: Removing Bearing Retainer Rear
    G02614737Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE LOCK BALL ASSY NO.1 
    1. Remove the lock ball assy No.1 from the manual transmission case.
    Fig 33: Removing Lock Ball Assy
    G02614738Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE SHIFT & SELECT LEVER SHAFT ASSY 
    1. Remove the 4 bolts and shift & select lever shaft assy and gasket from the manual transmission case.
    Fig 34: Removing Bolts
    G02614739Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE BACK UP LAMP SWITCH ASSY 
    1. Using SST, remove the back up lamp switch assy and gasket from the manual transmission case.

      SST 09817-16011

    Fig 35: Removing Back Up Lamp Switch Assy
    G02614740Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  31. REMOVE SHIFT DETENT BALL 
    1. Using a socket hexagon wrench (6 mm), remove the 2 shift detent ball plugs from the manual transmission case.
      Fig 36: Removing Shift Detent Ball
      G02614741Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a magnetic finger, remove the 2 shift detent ball compression spring seats, 2 shift detent ball compression springs and 2 shift detent balls from the manual transmission case.
    Fig 37: Removing 2 Shift Detent Ball Compression Spring
    G02614742Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  32. REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING 
    1. Using a snap ring expander, remove the output shaft rear bearing hole snap ring from the output shaft.
    Fig 38: Removing Output Shaft Rear Bearing Hole Snap Ring
    G02614743Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. REMOVE INPUT SHAFT REAR BEARING HOLE SNAP RING 
    1. Using a snap ring expander, remove the input shaft rear bearing hole snap ring.
    Fig 39: Removing Input Shaft Rear Bearing Hole Snap Ring
    G02614744Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  34. REMOVE MANUAL TRANSMISSION CASE PLUG 
    1. Using a socket hexagon wrench 6 mm, remove the manual transmission case plug from the manual transmission case.
    Fig 40: Removing Manual Transmission Case Plug
    G02614745Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. REMOVE REVERSE RESTRICT PIN PLUG 
    1. Using a socket hexagon wrench 6 mm, remove the reverse restrict pin plug from the manual transmission case.
    Fig 41: Removing Reverse Restrict Pin Plug
    G02614746Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  36. REMOVE REVERSE IDLER GEAR SHAFT BOLT 
    1. Remove the reverse idler gear shaft bolt and gasket from the manual transmission case.
    Fig 42: Removing Reverse Idler Gear Shaft Bolt
    G02614747Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  37. REMOVE MANUAL TRANSMISSION CASE 
    1. Remove the 3 bolts from the transaxle case side.
      Fig 43: Removing Bolts
      G02614748Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 13 bolts from the manual transmission case side.
      Fig 44: Removing Bolts
      G02614749Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and a hammer, remove the manual transmission case from the transaxle case.
    Fig 45: Removing Manual Transmission Case
    G02614750Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  38. REMOVE OIL RECEIVER PIPE NO.1 (MTM) 
    1. Remove the bolt and oil receiver pipe No.1 from the manual transmission case.
    NOTE: Be careful not to damage the oil receiver pipe No.1.
    Fig 46: Removing Oil Receiver Pipe
    G02614751Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  39. REMOVE OIL RECEIVER PIPE NO.2 (MTM) 
    1. Remove the bolt and oil receiver pipe No.2 from the manual transmission case.
    NOTE: Be careful not to damage the oil receiver pipe No.2.
    Fig 47: Removing Bolt Oil Receiver Pipe
    G02614752Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  40. REMOVE SHIFT DETENT BALL 
    1. Using a socket hexagon wrench (6 mm), remove the shift detent ball plug from the transaxle case.
      Fig 48: Removing Shift Detent Ball Plug
      G02614753Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a magnetic finger, remove the shift detent ball spring seat, shift detent ball compression spring and shift detent ball from the transaxle case.
    Fig 49: Removing Shift Detent Ball Spring Seat
    G02614754Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  41. REMOVE GEAR SHIFT FORK SHAFT SUB-ASSY NO.1 
    1. Using 2 screwdrivers and a hammer, remove the shaft snap ring.
      NOTE: Use a shop rag to keep the snap ring from flying.
      Fig 50: Removing Shaft Snap Ring
      G02614755Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gear shift fork lock bolt and gear shift fork shaft sub-assy No.1.
    Fig 51: Removing Gear Shift Fork Lock Bolt And Gear Shift Fork Shaft Sub-Assy
    G02614756Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  42. REMOVE GEAR SHIFT FORK SHAFT NO.3 
    1. Remove the shift fork shaft No.3 from the transaxle case.
      Fig 52: Removing Gear Shift Fork Shaft
      G02614757Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using 2 screwdrivers and a hammer, remove the shaft snap ring from the shift fork shaft No.3.
    NOTE: Use a shop rag to keep the snap ring from flying.
    Fig 53: Removing Shaft Snap Ring
    G02614758Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  43. REMOVE GEAR SHIFT FORK SHAFT NO.2 
    1. Remove the 2 gear shift fork lock bolts from the gear shift fork No.2 and gear shift head No.1.
      Fig 54: Removing Gear Shift Fork Shaft
      G02614759Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the gear shift fork shaft No.2, gear shift fork No.2, gear shift fork No.1, gear shift head No.1 and reverse shift fork.
    Fig 55: Removing Gear Shift Fork Shaft
    G02614760Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  44. REMOVE REVERSE IDLER GEAR SUB-ASSY 
    1. Remove the reverse idler gear shaft, thrust washer and reverse idler gear sub-assy from the transaxle case.
    Fig 56: Removing Reverse Idler Gear Sub-Assy
    G02614761Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  45. REMOVE INPUT SHAFT ASSY 
    1. Remove the input shaft assy with the output shaft assy from the transaxle case.
    Fig 57: Removing Input Shaft Assy
    G02614762Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  46. REMOVE REVERSE SHIFT ARM BRACKET ASSY 
    1. Remove the 2 bolts and reverse shift arm bracket assy from the transaxle case.
    Fig 58: Removing Bolts Reverse Shift Arm Bracket Assy
    G02614763Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  47. REMOVE DIFFERENTIAL CASE ASSY 
    1. Remove the differential case assy from the transaxle case.
    Fig 59: Removing Differential Case Assy
    G02614764Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  48. REMOVE MANUAL TRANSAXLE CASE RECEIVER 
    1. Remove the bolt and manual transaxle case receiver from the transaxle case.
    Fig 60: Removing Bolt Manual Transaxle Case Receiver
    G02614765Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  49. REMOVE BEARING LOCK PLATE 
    1. Remove the bolt and bearing lock plate from the transaxle case.
    Fig 61: Removing Bolt Bearing Lock Plate
    G02614766Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  50. REMOVE TRANSMISSION MAGNET 
    1. Remove the transmission magnet from the transaxle case.
    Fig 62: Removing Transmission Magnet
    G02614767Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  51. REMOVE INPUT SHAFT FRONT BEARING 
    1. Using SST, remove the input shaft front bearing (outer race) from the transaxle case.

      SST 09612-24014 (09613-22011)

    Fig 63: Removing Input Shaft Front Bearing
    G02614768Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  52. REMOVE FRONT TRANSAXLE CASE OIL SEAL 
    1. Using SST, remove the front transaxle case oil seal from the transaxle case.

      SST 09612-65014 (09612-01040, 09612-01050)

    Fig 64: Removing Front Transaxle Case Oil Seal
    G02614769Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  53. REMOVE OUTPUT SHAFT FRONT BEARING 
    1. Using SST, remove the output shaft front bearing from the transaxle case.

      SST 09308-00010

    NOTE: Do not apply excessive force to the transaxle case when installing it.
    Fig 65: Removing Output Shaft Front Bearing
    G02614770Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  54. REMOVE FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST, remove the front differential case rear tapered roller bearing (outer race) and shim from the manual transmission case.

      SST 09612-65014 (09612-01040, 09612-01050)

      Fig 66: Removing Front Differential Case Rear Tapered Roller Bearing
      G02614771Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the FR differential case rear tapered roller bearing (inner race) from the front differential case.

      SST 09612-65014 (09612-01040, 09612-01050), 09950-40011 (09951-00390, 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04061, 09957-04010, 09958-04011), 09950-60010

    Fig 67: Removing FR Differential Case Rear Tapered Roller Bearing
    G02614772Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  55. REMOVE TRANSMISSION CASE OIL SEAL 
    1. Using SST and a hammer, remove the transmission case oil seal from the manual transmission case.

      SST 09950-60010 (09951-00530), 09950-70010 (09951-07150)

    Fig 68: Removing Transmission Case Oil Seal
    G02614773Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  56. REMOVE FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST, remove the front differential case front tapered roller bearing (outer race) and front differential case front plate washer from the transaxle case.

      SST 09612-65014 (09612-01040, 09612-01050)

      Fig 69: Removing Front Differential Case Front Tapered Roller Bearing
      G02614774Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST, remove the FR differential case front tapered roller bearing (inner race) from the front differential case.

      SST 09950-00020, 09950-00030, 09950-40011 (09957-04010), 09950-60010 (09951-00390)

    Fig 70: Removing FR Differential Case Front Tapered Roller Bearing
    G02614775Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  57. REMOVE TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, remove the transaxle case oil seal from the transaxle case.

      SST 09950-60010 (09951-00600), 09950-70010 (09951-07100)

    Fig 71: Removing Transaxle Case Oil Seal
    G02614776Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  58. REMOVE OUTPUT SHAFT (MTM) COVER 
    1. Remove the output (MTM) shaft cover from the transaxle case.
    Fig 72: Removing Output Shaft Cover
    G02614777Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  59. REMOVE TRANSMISSION HUB SLEEVE NO.3 
    1. Remove the transmission hub sleeve No.3, 3 synchro-mesh shifting key No.3 and 2 synchromesh shifting key spring No.3.
    NOTE: Use a shop rag to keep the synchromesh shifting key and spring from flying.
    Fig 73: Removing Transmission Hub Sleeve
    G02614778Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  60. INSPECT TRANSMISSION HUB SLEEVE NO.3 
    1. Check the sliding condition between the transmission hub sleeve No.3 and transmission clutch hub No.3.
    2. Check that the tip of the spline gear of the transmission hub sleeve No.3 is not worn down.
      Fig 74: Inspecting Transmission Hub Sleeve
      G02614779Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using vernier calipers, measure the width of the transmission hub sleeve No.3 groove (A) and the thickness of the claw part on the gear shift fork No.3 (B), and calculate the clearance.

      Standard clearance (A - B): 

      0.31 to 0.89 mm (0.0122 to 0.035 in.) 

    If the clearance is out of specification, replace the transmission hub sleeve No.3 and gear shift fork No.3.

    Fig 75: Measuring Width Of Transmission Hub Sleeve
    G02614780Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  61. INSPECT SYNCHRONIZER RING NO.3 (FOR 6th GEAR MT) 
    1. Check for wear or damage.
    2. Coat the 6th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 6th gear cone. Check that the ring locks.

      If the synchronizer outer ring does not lock, replace the ring or the 6th gear.

      Fig 76: Inspecting Synchronizer Ring
      G02614781Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.

      Standard clearance: 

      0.75 to 1.65 mm (0.0295 to 0.065 in.) 

    If the clearance is out of specification, replace the synchronizer ring No.3.

    Fig 77: Measuring Clearance
    G02614782Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  62. INSPECT 6th GEAR SUB-ASSY 
    1. Using a caliper gauge, measure the 6th gear inner diameter.
    INNER DIAMETER REFERENCE

    New gear: mm (in.) Maximum inner diameter: mm (in.)
    28.015 to 28.031 (1.1030 to 1.1036) 28.031 (1.1036)

    If the clearance exceeds the maximum, replace the 6th gear sub-assy.

    Fig 78: Measuring Gear Inner Diameter
    G02614783Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  63. INSPECT SYNCHRONIZER RING NO.3 (FOR 5th GEAR MT) 
    1. Coat the 5th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 5th gear cone. Check that the ring locks.

      If the synchronizer outer ring does not lock, replace the ring or the 5th gear.

      Fig 79: Inspecting Synchronizer Ring
      G02614784Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a feeler gauge, measure the clearance between the synchronizer ring back and 5th gear spline end.

      Standard clearance: 

      0.75 to 1.65 mm (0.0295 to 0.0650 in.) 

    If the clearance is out of specification, replace the synchronizer ring No.3.

    Fig 80: Measuring Clearance
    G02614785Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  64. INSPECT 5th GEAR 
    1. Using a caliper gauge, measure the 5th gear inner diameter.
    INNER DIAMETER REFERENCE

    New gear: mm (in.) Maximum inner diameter: mm (in.)
    29.915 to 29.931 (1.1778 to 1.1784) 29.931 (1.1784)

    If the inner diameter exceeds the maximum, replace the 5th gear.

    Fig 81: Measuring Gear Inner Diameter
    G02614786Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  65. INSPECT REVERSE IDLER GEAR SUB-ASSY 
    1. Using a caliper gauge, inspect the reverse idler gear sub-assy as shown in the illustration.
      INNER DIAMETER REFERENCE

      New gear: mm (in.) Maximum inner diameter: mm (in.)
      18.040 to 18.058 (0.7102 to 0.7109) 18.058 (0.7109)

      If the inner diameter exceeds the maximum, replace the reverse idler gear sub-assy

    2. Using a micrometer, inspect the reverse idler gear shaft as shown in the illustration.
    OUTER DIAMETER REFERENCE

    New idler gear shaft: mm (in.) Minimum outer diameter: mm (in.)
    17.966 to 17.984 (0.7073 to 0.7080) 17.966 (0.7073)

    If the outer diameter is less than the minimum, replace the reverse idler gear shaft.

    Fig 82: Measuring Inner Diameter
    G02614787Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  66. INSTALL TRANSMISSION HUB SLEEVE NO.3 
    1. Coat the transmission hub sleeve No.3 with gear oil, and install it to the transmission clutch hub No.3.
      NOTE: Do not set the transmission clutch hub No.3 in an incorrect orientation.
    2. Using a screwdriver, install the 2 synchromesh shifting key spring No.3 and 3 synchromesh shifting key No.3.
    NOTE: Do not set the openings of the shifting key springs in the same position.
    Fig 83: Installing Synchromesh Shifting Key Spring
    G02614788Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  67. INSTALL OUTPUT SHAFT (MTM) COVER 
    1. Coat the output shaft (MTM) cover with MP grease, and install it to the transaxle case.
    Fig 84: Installing Output Shaft Cover
    G02614789Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  68. INSTALL TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, install the transaxle case oil seal to the transaxle case.

      SST 09726-27012 (09726-02041), 09950-70010 (09951-07100)

      Driven in depth: 1.6 to 2.2 mm (0.063 to 0.087 in.) 

    Fig 85: Installing Transaxle Case Oil Seal
    G02614790Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  69. INSTALL FR DIFFERENTIAL CASE FRONT TAPERED ROLLER BEARING 
    1. Using SST and a press, install the FR differential case front tapered roller bearing (inner race) to the front differential case.

      SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)

      Fig 86: Installing FR Differential Case Front Tapered Roller Bearing
      G02614791Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install the front differential case front plate washer and FR differential case front tapered roller bearing (outer race) to the transaxle case.

      SST 09950-60020 (09951-00680), 09950-70010 (09951-07150)

    Fig 87: Installing Front Differential Case Front Plate Washer
    G02614792Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  70. INSTALL FR DIFFERENTIAL CASE REAR TAPERED ROLLER BEARING 
    1. Using SST and a press, install the FR differential case rear tapered roller bearing (inner race) to the front differential case.

      SST 09350-32014 (09351-32120), 09950-60010 (09951-00530)

      Fig 88: Installing FR Differential Case Rear Tapered Roller Bearing
      G02614793Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, install the front differential case rear plate washer and FR differential case rear tapered roller bearing (outer race) to the manual transmission case.

      SST 09309-36010, 09950-60020 (09951-00710), 09950-70010 (09951-07150)

    Fig 89: Installing Front Differential Case Rear Plate Washer
    G02614794Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  71. INSTALL OUTPUT SHAFT FRONT BEARING 
    1. Coat a new output shaft front bearing with gear oil, and using SST and a press, install it to the transaxle case.

      SST 09950-60010 (09951-00550), 09950-70010 (09951-07150)

    Fig 90: Installing Output Shaft Front Bearing
    G02614795Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  72. ADJUST DIFFERENTIAL SIDE BEARING PRELOAD 
    1. Coat the differential case assy with gear oil, and install it to the transaxle case.
    2. Install the manual transmission case with the 16 bolts.

      Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 

      Fig 91: Installing Bolts
      G02614796Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using SST and a torque wrench, turn the differential case assy right and left 2 or 3 times to allow the bearings to settle.

      SST 09564-32011

      Fig 92: Turning Differential Case Assy
      G02614797Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using SST and a torque wrench, measure the preload.

      SST 09564-32011

      PRELOAD REFERENCE

      Bearing Torque
      New 0.78 to 1.57 N.m (8 to 16 kgf.cm, 7 to 14 in..lbf)
      Used 0.49 to 0.98 N.m (5 to 10 kqf.cm, 4 to 9 in..lbf)

      If the preload is out of specification, select a proper front differential case rear plate washer and adjust it.

      Fig 93: Measuring Preload
      G02614798Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

      HINT:

      WASHER THICKNESS REFERENCE

      Part No. Thickness: mm (in.) Make
      90564-41014 2.10 (0.0827) AA
      90564-41015 2.15 (0.0846) BB
      90564-41016 2.20 (0.0866) CC
      90564-41017 2.25 (0.0886) DD
      90564-41018 2.30 (0.0906) EE
      90564-41019 2.35 (0.0925) FF
      90564-41020 2.40 (0.0945) GG
      90564-41021 2.45 (0.0965) HH
      90564-41022 2.50 (0.0984) JJ
      WASHER THICKNESS REFERENCE

      Part No. Thickness: mm (in.) Make
      90564-41023 2.55 (0.1004) KK
      90564-41024 2.60 (0.1024) LL
      90564-41025 2.65 (0.1043) MM
      90564-41026 2.70 (0.1063) NN
      90564-11027 2.75 (0.1083) PP
      90564-41028 2.80 (0.1102) QQ
      90564-41029 2.85 (0.1122) RR
      90564-41030 2.90 (0.1142) SS
      90564-41031 2.95 (0.1161) TT
      90564-41032 3.00 (0.1181) UU
    5. Remove the 16 bolts and manual transmission case.
    6. Remove the differential case assy from the transaxle case.
  73. INSTALL FRONT TRANSAXLE CASE OIL SEAL 
    1. Using SST and a hammer, install a new front transaxle case oil seal to the transaxle case.

      SST 09950-60010 (09951-00370), 09950-70010 (09951-07150)

      Driven in depth: 15.6 to 16.0 mm (0.6142 to 0.6299 in.) 

    2. Coat the lip of the front transaxle case oil seal with MP grease.
    Fig 94: Installing Front Transaxle Case Oil Seal
    G02614799Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  74. INSTALL INPUT SHAFT FRONT BEARING 
    1. Coat a new input shaft front bearing with gear oil, and using SST and a press, install it to the transaxle case.

      SST 09950-60010 (09951-00420), 09950-70010 (09951-07150)

      Driven in depth: 0 to 0.30 mm (0 to 0.0118 in.) 

    Fig 95: Installing Input Shaft Front Bearing
    G02614800Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  75. INSTALL TRANSMISSION MAGNET 
    1. Clean the transmission magnet, and install it to the transaxle case.
    Fig 96: Installing Transmission Magnet
    G02614801Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  76. INSTALL BEARING LOCK PLATE 
    1. Install the bearing lock plate with the bolt to the transaxle case.

      Torque: 11 N.m (115 kgf.cm, 8 ft.lbf) 

    Fig 97: Installing Bearing Lock Plate
    G02614802Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  77. INSTALL MANUAL TRANSAXLE CASE RECEIVER 
    1. Install the manual transaxle case receiver with the bolt to the transaxle case.

      Torque: 11 N.m (115 kgf.cm, 8 ft.lbf) 

    Fig 98: Installing Manual Transaxle Case Receiver Bolt
    G02614803Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  78. INSTALL DIFFERENTIAL CASE ASSY 
    1. Coat the differential case tapered roller bearing with gear oil, and install the differential case assy to the transaxle case.
    Fig 99: Installing Differential Case Assy
    G02614804Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  79. INSTALL REVERSE SHIFT ARM BRACKET ASSY 
    1. Install the reverse shift arm bracket assy with the 2 bolts to the transaxle case.

      Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 

    Fig 100: Installing Reverse Shift Arm Bracket Assy Bolt
    G02614805Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  80. INSTALL INPUT SHAFT ASSY 
    1. Coat the sliding and rotating surfaces of the input and output shafts with gear oil, and install them to the transaxle case.
    Fig 101: Installing Input Shaft Assy
    G02614806Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  81. INSTALL REVERSE IDLER GEAR SUB-ASSY 
    1. Coat the reverse idler gear sub-assy, thrust washer and reverse idler gear shaft with gear oil, and install them to the transaxle case.

    HINT:

    Align the mark on the reverse idler gear shaft with the bolt hole shown in the illustration.

    Fig 102: Installing Reverse Idler Gear Sub-Assy
    G02614807Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  82. INSTALL GEAR SHIFT FORK SHAFT NO.2 
    1. Coat the gear shift fork No.2 and gear shift fork No.1 with gear oil, and install them to the input and output shafts.
      Fig 103: Installing Gear Shift Fork Shaft
      G02614808Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the gear shift fork shaft No.2 with gear oil, and install the gear shift head No.1, reverse shift fork and gear shift fork shaft No.2.
      Fig 104: Installing Gear Shift Head
      G02614809Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Coat the 2 shift lock bolts with sealant, and install them to the gear shift fork No.2 and gear shift head No.1.

      Sealant: 

      Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 

    Fig 105: Installing Shift Lock Bolts
    G02614810Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  83. INSTALL GEAR SHIFT FORK SHAFT NO.3 
    1. Using a brass bar and a hammer, install the shaft snap ring to the gear shift fork shaft No.3.
      Fig 106: Installing Shaft Snap Ring
      G02614811Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the gear shift fork shaft No.3 with gear oil, and install it to the transaxle case.
    Fig 107: Installing Gear Shift Fork Shaft
    G02614812Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  84. INSTALL GEAR SHIFT FORK SHAFT SUB-ASSY NO.1 
    1. Coat the gear shift fork shaft sub-assy No.1 with gear oil, and install it to the transaxle case.
    2. Coat the shift fork lock bolt with sealant, and install it to the gear shift fork No.1.

      Sealant: 

      Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 

      Fig 108: Installing Gear Shift Fork Shaft Sub-Assy
      G02614813Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and a hammer, install the shaft snap ring.
    Fig 109: Installing Shaft Snap Ring
    G02614814Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  85. INSTALL SHIFT DETENT BALL 
    1. Install the shift detent ball, shift detent ball compression spring and shift detent ball compression spring seat to the transaxle case.
      Fig 110: Installing Shift Detent Ball
      G02614815Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the shift detent ball plug with sealant, and using SST, install it to the transaxle case.

      Sealant: 

      Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 22 N.m (224 kgf.cm, 16 ft.lbf) 

    Fig 111: Installing Shift Detent Ball Plug
    G02614816Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  86. INSTALL OIL RECEIVER PIPE NO.2 (MTM) 
    1. Install the oil receiver pipe No.2 (MTM) with the bolt to the manual transmission case.

      Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 

    Fig 112: Installing Oil Receiver Pipe Bolt
    G02614817Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  87. INSTALL OIL RECEIVER PIPE NO.1 (MTM) 
    1. Install the oil receiver pipe No.1 (MTM) with the bolt to the manual transmission case.

      Torque: 17 N.m (175 kgf.cm, 13 ft.lbf) 

    Fig 113: Installing Oil Receiver Pipe Bolt
    G02614818Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  88. INSTALL MANUAL TRANSMISSION CASE 
    1. Apply FIPG to the manual transmission case, as shown in the illustration.

      FIPG: 

      Part No.08826-00090, THREE BOND 1281 or equivalent 

      Fig 114: Applying FIPG
      G02614819Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
    2. Install the 13 bolts to the manual transmission side. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf)
      Fig 115: Installing Bolts
      G02614820Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the 3 bolts to the transaxle case side.

      Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 

    Fig 116: Installing Bolts
    G02614821Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  89. INSTALL REVERSE IDLER GEAR SHAFT BOLT 
    1. Coat the reverse idler gear shaft bolt with sealant, and install it with a new gasket to the manual transmission case.

      Sealant: 

      Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 

    Fig 117: Installing Reverse Idler Gear Shaft Bolt
    G02614822Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  90. INSTALL MANUAL TRANSMISSION CASE PLUG 
    1. Coat the transmission case plug with sealant, and using a socket hexagon wrench (6 mm), install it to the manual transmission case.

      Sealant: 

      Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

    Fig 118: Installing Manual Transmission Case Plug
    G02614823Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  91. INSTALL REVERSE RESTRICT PIN PLUG 
    1. Coat the reverse restrict pin plug with sealant, and using a socket hexagon wrench (6 mm), install it to the manual transmission case.

      Sealant: 

      Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 29 N.m (296 kgf.cm, 21 ft.lbf) 

    Fig 119: Installing Reverse Restrict Pin Plug
    G02614824Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  92. INSTALL INPUT SHAFT REAR BEARING HOLE SNAP RING 
    1. Using a snap ring expander, install the input shaft rear bearing hole snap ring to the input shaft.
    Fig 120: Installing Input Shaft Rear Bearing Hole Snap Ring
    G02614825Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  93. INSTALL OUTPUT SHAFT REAR BEARING HOLE SNAP RING 
    1. Using a snap ring expander, install the output shaft rear bearing hole snap ring to the output shaft.
    Fig 121: Installing Output Shaft Rear Bearing Hole Snap Ring
    G02614826Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  94. INSTALL TRANSMISSION CASE OIL SEAL 
    1. Using SST and a hammer, install the transmission case oil seal to the manual transmission case.

      SST 09316-60011 (09316-00011)

      Driven in depth: 9.6 to 10.2 mm (0.378 to 0.402 in.) 

    2. Coat the lip of the transmission case oil seal with MP grease.
    Fig 122: Installing Transmission Case Oil Seal
    G02614827Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  95. INSTALL SHIFT DETENT BALL 
    1. Install the 2 shift detent balls, 2 shift detent ball springs and 2 shift detent ball spring seats to the manual transmission case.
      Fig 123: Installing Shift Detent Ball
      G02614828Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the 2 shift detent ball plugs with sealant, and install them to the manual transmission case.

      Sealant: 

      Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 22 N.m (224 kgf.cm, 16 ft.lbf) 

    Fig 124: Installing Shift Detent Ball Plugs
    G02614829Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  96. INSTALL BACK UP LAMP SWITCH ASSY 
    1. Using SST, install the back up lamp switch assy with a new gasket to the manual transmission case.

      SST 09817-16011

      Torque: 40 N.m (411 kgf.cm, 30 ft.lbf) 

    Fig 125: Installing Back Up Lamp Switch Assy
    G02614830Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  97. INSTALL SHIFT & SELECT LEVER SHAFT ASSY 
    1. Coat the shift & select lever shaft assy with gear oil.
    2. Coat the 2 bolts with sealant, and install them and 2 bolts with a new gasket and shift & select lever shaft assy.

      Sealant: 

      Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 

    Fig 126: Installing Bolt
    G02614831Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  98. INSTALL LOCK BALL ASSY NO.1 
    1. Coat the lock ball assy No.1 with sealant, and install it to the manual transmission case.

      Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) 

    Fig 127: Installing Lock Ball Assy
    G02614832Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  99. INSTALL BEARING RETAINER REAR (MTM) 
    1. Coat the 5 bolts with sealant, and install the bearing retainer rear to the manual transmission case with the bolts.

      Sealant: 

      Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent 

      Torque: 27 N.m (279 kgf.cm, 20 ft.lbf) 

    Fig 128: Installing Bearing Retainer Rear
    G02614833Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  100. INSTALL SHIFT FORK SHAFT SNAP RING 
    1. Using a brass bar and a hammer, install the shift fork shaft snap ring to the shift fork shaft No.2.
    Fig 129: Installing Shift Fork Shaft Snap Ring
    G02614834Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  101. INSTALL 5th DRIVEN GEAR 
    1. Using SST, install the 5th driven gear to the output shaft.

      SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03080)

    Fig 130: Installing 5th Driven Gear
    G02614835Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  102. INSTALL OUTPUT GEAR SPACER 
    1. Install the output gear spacer to the output shaft.
    Fig 131: Installing Output Gear Spacer
    G02614836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  103. INSTALL 5th GEAR NEEDLE ROLLER BEARING 
    1. Coat the two 5th gear bearing spacers and 5th gear needle roller bearing with gear oil, and install them to the input shaft.
      Fig 132: Installing 5th Gear Needle Roller Bearing
      G02614837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using a brass bar and a hammer, install the transmission clutch hub No.3 shaft snap ring to the input shaft.
    Fig 133: Installing Transmission Clutch Hub
    G02614838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  104. INSTALL 5th GEAR 
    1. Coat the 5th gear with gear oil, and install it to the input shaft.
    Fig 134: Installing 5th Gear
    G02614839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  105. INSTALL SYNCHRONIZER RING NO.3 (FOR 5th GEAR MT) 
    1. Coat the synchronizer ring No.3 with gear oil, and install it to the 5th gear.
    Fig 135: Installing Synchronizer Ring
    G02614840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  106. INSTALL TRANSMISSION CLUTCH HUB NO.3 
    1. Using SST and a hammer, install the transmission clutch hub No.3 with the gear shift fork No.3 to the input shaft.

      SST 09608-04031

      NOTE:
      • Before driving in the transmission clutch hub No.3, place the suitable sized wooden block under the rear side of the input shaft, as shown in the illustration.
      • When driving it in, fix the input shaft firmly so that it is not pushed downward. Otherwise the input shaft rear bearing is over loaded and might be damaged.
      Fig 136: Installing Transmission Clutch Hub
      G02614841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Coat the shift fork lock bolt with sealant, and install it to the gear shift fork No.3.

      Torque: 16 N.m (160 kgf.cm, 12 ft.lbf) 

      Fig 137: Installing Shift Fork Lock Bolt
      G02614842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Select the snap ring that allows the minimum amount of axial play.

      Clearance: 0.1 mm (0.004 in.) or less 

      SNAP RING THICKNESS SPECIFICATION

      Part No. Thickness: mm (in.) Mark
      90520-20074 1.75 (0.0689) A
      90520-20075 1.80 (0.0709) B
      90520-20076 1.85 (0.0728) C
      90520-20077 1.90 (0.0748) D
      90520-20078 1.95 (0.0768) E
      90520-20079 2.00 (0.0787) F
      90520-20080 2.05 (0.0807) G
      90520-20081 2.10 (0.0827) H
      90520-20082 2.15 (0.0846) J
      Fig 138: Installing Transmission Clutch Hub
      G02614843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Using a brass bar and a hammer, install the transmission clutch hub No.3 snap ring to the input shaft.
  107. INSTALL COUNTER GEAR 6th 
    1. Using SST, install the counter gear 6th to the output shaft.

      SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03080)

    Fig 139: Installing Counter Gear 6th
    G02614844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  108. INSTALL SYNCHRONIZER RING NO.3 (FOR 6th GEAR MT) 
    1. Coat the synchronizer ring No.3 with gear oil, and install it to the transmission clutch hub No.3.
    Fig 140: Installing Synchronizer Ring
    G02614845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  109. INSTALL 6th GEAR NEEDLE ROLLER BEARING 
    1. Coat the 6th gear needle roller bearing and 6th gear spacer with gear oil, and install them to the input shaft.
    Fig 141: Installing 6th Gear Needle Roller Bearing
    G02614846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  110. INSTALL 6th GEAR SUB-ASSY 
    1. Coat the 6th gear sub-assy with gear oil, and install it to the input shaft.
    Fig 142: Installing 6th Gear Sub-Assy
    G02614847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  111. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING 
    1. Using SST, a steel block and a hammer, install the input shaft rear radial ball bearing to the input shaft.

      SST 09608-04031

      Fig 143: Installing Input Shaft Rear Radial Ball Bearing
      G02614848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select the input shaft snap ring that allows the minimum amount of axial play.

      Clearance: 0.1 mm (0.004 in.) or less 

      SNAP RING THICKNESS SPECIFICATION

      Part No. Thickness: mm (in.) Mark
      90520-17006 1.70 (0.0669) A
      90520-17007 1.75 (0.0689) B
      90520-17008 1.80 (0.0709) C
      90520-17009 1.85 (0.0728) D
      90520-17010 1.90 (0.0748) E
      90520-17011 1.95 (0.0768) F
      90520-17012 2.00 (0.0787) G
      90520-17013 2.05 (0.0807) H
      90520-17014 2.10 (0.0827) J
      90520-17015 2.15 (0.0846) K
      90520-17016 2.20 (0.0866) L
      90520-17017 2.25 (0.0886) M
      Fig 144: Installing Input Shaft Snap Ring
      G02614849Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and hammer, install the input shaft snap ring to the input shaft.
  112. INSTALL OUTPUT SHAFT REAR BEARING 
    1. Using SST, install the output shaft rear bearing to the output shaft.

      SST 09950-30012 (09951-03010, 09953-03010, 09954-03010, 09955-03011, 09956-03080)

      Fig 145: Installing Output Shaft Rear Bearing
      G02614850Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Select the output shaft RR snap ring that allows the minimum amount of axial play.

      Clearance: 0.1 mm (0.004 in.) or less 

      SNAP RING THICKNESS SPECIFICATION

      Part No. Thickness: mm (in.) Mark
      90520-18003 2.31 (0.0909) B
      90520-18004 2.37 (0.0933) C
      90520-18006 2.43 (0.0957) D
      90520-18007 2.49 (0.0980) E
      90520-18008 2.55 (0.1004) F
      90520-18009 2.61 (0.1028) G
      90520-18013 2.67 (0.1051) H
      90520-18011 2.73 (0.1075) J
      90520-18014 2.79 (0.1098) K
      90520-18015 2.85 (0.1122) L
      90520-18016 2.91 (0.1146) M
      Fig 146: Installing Output Shaft RR Snap Ring
      G02614851Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Using a brass bar and hammer, install the output shaft RR snap ring to the output shaft.
  113. INSPECT 5th GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 5th gear radial clearance.

      Standard clearance: 

      0.015 to 0.056 mm (0.0006 to 0.0022 in.) 

    If the clearance is out of specification, replace the 5th gear needle roller bearing.

    Fig 147: Measuring 5th Gear Radial Clearance
    G02614852Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  114. INSPECT 6th GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 6th gear radial clearance.

      Standard clearance: 

      0.009 to 0.050 mm (0.0004 to 0.0020 in.) 

    If the clearance is out of specification, replace the 6th gear needle roller bearing.

    Fig 148: Measuring 6th Gear Radial Clearance
    G02614853Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  115. INSPECT 5th GEAR THRUST CLEARANCE 
    1. Using a dial indicator, measure the 5th gear thrust clearance.

      Standard clearance: 

      0.10 to 0.62 mm (0.0039 to 0.0244 in.) 

    Fig 149: Measuring 5th Gear Thrust Clearance
    G02614854Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  116. INSPECT 6th GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 6th gear thrust clearance.

      Standard clearance: 

      0.10 to 0.60 mm (0.0039 to 0.0236 in.) 

    Fig 150: Measuring 6th Gear Thrust Clearance
    G02614855Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  117. INSTALL MANUAL TRANSMISSION CASE COVER SUB-ASSY 
    1. Apply FIPG to the manual transmission case cover sub-assy.

      FIPG: 

      Parts No.08826-00090, THREE BOND 1281 or equivalent 

      Fig 151: Applying FIPG
      G02614856Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
      NOTE: Parts must be assembled within 10 minutes of application. Otherwise, the packing (FIPG) material must be removed and reapplied.
    2. Install the manual transmission case cover sub-assy with the 9 bolts to the manual transmission case.

      Torque: 18 N.m (185 kgf.cm, 13 ft.lbf) 

    Fig 152: Installing Bolts
    G02614857Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  118. INSTALL DRAIN (MTM) PLUG SUB-ASSY 
    1. Install the drain (MTM) plug sub-assy with a new gasket to the manual transmission case.

      Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

    Fig 153: Installing Drain Plug Sub-Assy
    G02614858Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  119. INSTALL MANUAL TRANSMISSION FILLER PLUG 
    1. Install the manual transmission filler plug with a new gasket to the manual transmission case cover.

      Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 

    Fig 154: Installing Manual Transmission Filler Plug
    G02614859Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  120. INSTALL SELECTING BELL CRANK ASSY 
    1. Install the selecting bell crank assy and control shift lever bush with the 2 bolts to the manual transmission case.

      Torque: 25 N.m (250 kgf.cm, 18 ft.lbf) 

    NOTE: Apply MP grease to the inside circumferential surface of the control shift lever bush (A).
    Fig 155: Installing Selecting Bell Crank Assy And Control Shift Lever Bush Bolts
    G02614860Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  121. INSTALL FLOOR SHIFT CONTROL LEVER HOUSING SUPPORT BRACKET 
    1. Install the floor shift control lever housing support bracket with the 3 bolts to the transaxle case.

      Torque: 18 N.m (184 kgf.cm, 13 ft.lbf) 

    Fig 156: Installing Floor Shift Control Lever Housing Support Bracket Bolts
    G02614861Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  122. INSTALL CLUTCH RELEASE FORK BOOT 
    1. Install the clutch release fork boot to the transaxle case.
    Fig 157: Installing Clutch Release Fork Boot
    G02614862Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  123. INSTALL RELEASE FORK SUPPORT 
    1. Install the release fork support to the transaxle case.

      Torque: 37 N.m (375 kgf.cm, 27 ft.lbf) 

    2. Coat the release fork support with release hub grease.

      Release hub grease: 

      Part No.08887-01806, RELEASE HUB GREASE or equivalent 

    Fig 158: Installing Release Fork Support
    G02614863Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  124. INSTALL CLUTCH RELEASE BEARING ASSY 
    1. Coat the clutch release bearing assy with release hub grease, and install it to the clutch release fork sub-assy with the bearing clip.

      Release hub grease: 

      Part No.08887-01806, RELEASE HUB GREASE or equivalent 

    Fig 159: Installing Clutch Release Bearing Assy
    G02614864Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  125. INSTALL CLUTCH RELEASE FORK SUB-ASSY 
    1. Apply clutch spline grease to the input shaft spline.

      Clutch spline grease: 

      Part No.08887-01806, CLUTCH SPLINE GREASE or equivalent 

    2. Install the clutch release fork sub-assy to the input shaft.
    Fig 160: Installing Clutch Release Fork Sub-Assy
    G02614865Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  126. INSTALL SPEEDOMETER DRIVEN HOLE COVER SUB-ASSY 
    1. Install a new O-ring to the speedometer driven hole cover sub-assy.
    2. Install the speedometer driven hole cover sub-assy with the bolt to the transaxle case.

      Torque: 11 N.m (115 kgf.cm, 8 ft.lbf) 

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